CAST-DESIGNER

Upfront design & analysis system for die casting

{
30 minuts to design one gating system

1 hour to validate a design solution

1 day to compare 4 to 5 solutions

Integration of expert system and CAE technology

Original casting A tailor-designed mould planning & simulation system for die casting industry

30 min

15 Cast-Designer is a quick casting design

min and analysis tool based on upfront design &
ana lys is te chnol ogy. The core o f th e
“upfront design & analysis technology” is to
allow engineers to conduct fluid flow, heat
transfer and solidification analysis by the
5 min assistance of combination of expert system
5 min
and CAE technology, it helps engineers to
make a “Right” engineering decision in the
early design stage of a project. Upfront
design & analysis technology has already
been becoming a very important role in
main stream design process.

With Cast-Designer, users can optimize a

ca st i ng d esi g n b y d et e ct i ng t he pa rt
features with potential flow and
60 min 60 min solidification problems, evaluating gate
system and overflow design alternatives in
the early design stage. Even a novel with
limited experience in simulation who can
easier to undertake the design setup in very
short period of time. In other word, Cast-
Designer can help the industry to achieve
the target of 'Time to Market'.

CAST-DESIGNER helps engineers to quickly convert ideas into 3D CAD

solid model, and subsequently evaluate the casting design. According to the
result of the CPI analysis, engineers can make critical modifications and
easily achieve a satisfactory design solution

C3P Engineering Software International All Rights Reserved 2011

STAMP-ENGINEER,CAST-ENGINEER, CAST-DESIGNER, STAMP-ES, is a trademark of C3P Engineering Software
International Co.,Limited. All other logos, trademarks used herein are the property of their respective owners.
 System module CAST-DESIGNER Basic
As a c ore component of CAST-DESIGNE R
system, CAST-DESIGNER Basic is an efficient
and flexible design tool which assists designers to
develop gating system for die casting in very short
time. With the help of CAST-DESIGNER, engineer
can quickly convert a gating system design idea
becoming a 3D model for design evaluation.
CAST-DESIGNER enable user easily to manage
and alter parameter for different stage whatever
for initial concept design stage, intermediate
embodiment design stage, or final design stage. It
is possible to create the full gating system
including inner gates, gate runners, runners,
overflows as well as cooling and venting systems
within tens minute to one hour for a typical casting
CAST-DESIGNER users interface, with OpenCASCADE CAD technology
part.
CAST-DESIGNER CPI
Based on its unique innovative technology, Cast-
Designer CPI (Casting Process Insight) is the sole really
practical tool on the marketing today to support designer
and engineer to make fast decision for casting part and
mould design. It is capable to reflect varieties of
dynamics and physical behaviors of fluid flow, heat
transfer and solidification in details. Comparing with
traditional numerical simulation, CPI is solely based on
CAD environment, and provides nearly real-time analysis
results. The beauty of CPI is the full couple with the
design functions of Cast-Designer and quickness to
obtain the analysis results at the conceptual design
stage. There may be many alternative designs, a quick
tool is important to run all designs and remove the poor
designs. Thus at this stage, the traditional numerical
simulation is not applicable.

Operation and Flow Chart of Gate System Design

2
Humane Draft Design

1
Gating System Design
Start design from draft paper and import to
Cast-Designer in any image format
Design Advisor Inner Gate Design
Support BMP, TIF or JPG format Guiding designer carries out the gating
Support both bitmap and vector formats, system design process in a simple way. Calculate the inner gate area with
Basing on the mass or volume of casting as Design Advisor
convert bitmap to vector data automatically well as geometry dimension and material
Inner gate area comparison in real
Support DXF, IGES as input type, the system can estimate the filling time
time
automatically, and guide to select the casting
Special designed tools for draft location and machine correctly to meet a reasonable filling Online tips and wizards with
size adjustment ratio of chamber. It also can predict the 1st industrial know-how and experience
and 2nd sp eed, crit ical sh ift point and
Online evaluation tools
calculate the final section areas for ingate,
gate-runner, runner and sprue runner. All the Suitable to ingate with complex
number of gates and runners could be geometry
evaluated and adjusted in real time.

Gate-Runner and Runner Design

(a) (b) (c)
Build in wizard to define flow path
and section parameters quickly
Example of draft design for gating system (a) original draft design (b) Support runner with fan, curve and
Working environment after load draft design and convert to vector data tangent
(c) The final gating system designed as draft idea.
Gating system design Generate feature sections in pre-
wizard to guide the defined curve or wire directly
whole gating design in Various styles in solid model
express and effective generation
way
Take account of the efficiency of
metal flow in runner design
(a)
(b)
Real time WYS/WYG visualization
for both 2D and 3D

Sprue runner designer

Support Cold and hot chamber
machine as well as no sprue runner
design (c)
Full parameterized and standard
design
(a) User interface of gating system designer, with full
Help select casting machine and parametric and streamline design (b) (c) Difference
estimate machine parameters design plans can be applied to the same casting for
Easily to customize plan comparison.

Checking and evaluation

4 Design revise and data management

1, Shift design from fix dies to movable

dies side
2, objects translation, rotation, mirror and
extrusion
3, Save/load and export/import full design
parameters
4, quick comparison of same casting with
multi-designs
5, help company generate own database.
For the similar part, load the past
template and make some necessary
modification can save at least 80%
workload.
Checking and evaluation

1, Sections and area of gating system

2, Filling ratio and yield ratio evaluation
3, Locking force and working parameters
of casting machine

Gating system, cooling system

and venting system design
3
Overflow
Overflow, cooling and venting system

1, Creates rectangular, orbicular and wedge

overflows , locations specified by designer
and pre-defined template to speed up
dimension define
2, Support multi-overflow sets. Overflows
could be translated, rotated, mirrored to a
new design
3, Support non-standard overflow design
4, Cooling and venting channel can be
generated basing on the pre-defined path
line or curve with a flexible sections define.
5, Build in wizard to calculate the total length
and section area of cooling line to achieve
heat transfer balance
6, Support cooling block design
CAST-DESIGNER Basic for MCAD CAST-DESIGNER CPI for MCAD CAST-DESIGNER / CPI MCAD
Cast-Designer for MCAD is used as a plug-in to fully With its unique technology, Cast-Designer CPI SUPPORT VERSION
integrate to the existing MCAD system for better can fully integrate CAE spectrum fluid flow
integration and data sharing. User can use their analysis, heat transfer and solidification with the CAD SYSTEM SUPPORT VERSION
normally used CAD system to create a part model and customer's existing MCAD user environment,
then input the model to Cast-Designer through the which enable product and mould designers Pro / ENGINEER 2000 - Wf5
MCAD bundle. While the gating design is completed, involving to the design process together and
user can input back the complete gating design setup mak ing engineering decision promptly and UG NX 17 - Nx7
to the MCAD system for fine-turning the design. In simultaneously.
this process, as long as operating in accordance with SolidWorks 2004 - 2010
MCAD regulations, there should be no any data loss, Simulation driven by CAD data : With the CPI in
and some advanced features of MCAD system could MCAD, your CAD geometry can drive the
Software language: English, Japanese, Chinese
be used for final CAD assembly, such as Boolean simulation process. When you make a design
operations, surface cleaning and filleting, etc. change in CAD system (such as Pro/E, UG NX or
Solidworks), you see the change in CPI in just a
few seconds. It's as simple as that.

Cast -De sign er fo r MCAD Same as the standalone Finally, the designed casting
was fully integrated into the v ers i on , Ca s t -De si g ne r sy st em wo ul d b e brou gh t
Pro -E sy s te m , af t e r t h e for MCAD has full back to Pro-E system
casting design, one button f u n ct io n s f o r c a s t i n g automatically for assembly or
can shift to Cast-Designer s ys t e m d e s i gn (g a t i n g l i n k t o C A M f o r
wo rki n g e n vi ron me n t f or system, overflow, cooling manufacturing. The
gat ing syst em design as and venting system), as advanced features of MCAD
well as the 3D casting data we l l a s b e tte r d at a system still could be used
coul d be tra nsferre d integration. f re e, s uch as B oo lea n
automatically. op er a ti on s, f il le ti ng an d
surface cleaning etc.

Upfront Analysis vs Tradition CAE Simulation Best in Class of CPI

It is well known the traditional numerical simulation is not applicable or very
expensive for the concept stage. The data to run a numerical simulation is
Solver Technology
usually not available yet, for example runner geometry. Due to the complexity
of the equation system to be solved, numerical simulation is too time Base on Finite Element Method (FEM) technology
consuming, usually hours or even days. Setup the simulation model is also a
heavy job. Numerical simulation provides a relatively high level accuracy, Fluid flow calculations are described by the full Navier-Stokes equation and
couple to thermal analysis
which is more than needed at conceptual design stage.
Simulate the physical phenomena and mechanical behavior of metal filling,
solidification and cooling process, such as temperature, velocity, pressure,
liquid/solid factors etc.
Innovation technology to speed up simulation in express, half hour to one half
hour for almost cases
Submit job to solver in directly and batch queue mode
Both 32 bits and 64 bits solvers, Windows and Linux
Support parallel computing technology for big or huge model

Cast-Designer do the best to make a balance on easily usage, robust and functions, the user can solve at
least 80% industrial problems in an express and effective way.
Model Setup
Excellent Mesh Technology Only one windows page to setup casting process, boundary condition and
control parameters for flow, heat transfer and solidification simulation
Very fast and robust meshing, fully automatically
With rich material data in database , casting and mould material could be
Flexible to control the element size in different direction (X/Y/Z) selected from database directly
Support multi solid geometries, no Boolean operation required before Pre-defined template for die casting process, as well as user can define the
meshing process in free, such as piston velocity, pressure, mould size and HTC etc.
CAD or mesh or mixed CAD & mesh as original data All conditions and parameters could be save as template file for future usage
Special treatment for CAD defects, such as geometry gap, overlay,
intersection or unclose
Advance technology for tin dimension or complex region
Advance mesh smoothing technology to match the geometry feature
Result & Reporting
Introduce special customized ParaVIEW as post-processors. ParaVIEW is a
famous software and used widely in HPC, it is very powerful and flexible
Rich analysis results in various formats, such as contours, vectors, sections and
curves, it is also support animation and VRML
Support plug-in filter for post-process, similar the concept of Photoshop
Mesh comparison of tradition FDM mesh (left) with Cast-Designer CPI mesh (right). Thanks
the advance coarse mesh and smooth mesh technology, CPI can make a best balance in mesh
quality and numbers to match the casting geometry feature.

Gate System Actual Part Shrinkage defects

CPI Mesh Flow Analysis Solidification Analysis & shrinkage defects

PROJECT AND DATA MANAGEMENT
Cast-Designer for MCAD brings the
project and data management to die
casting industrial. It is absolutely
important for designer and engineer.

Since so many design plans and

simulations will be carried out in the
practical engineering work, we can
not always use the filenames to
Mobile Phone Cover
manage data and projects, it is too
simple and makes confuse usually.
Also, how to generate the design and
simulation r epor t is also ver y
important.

F ou r l e ve l da t a st ru ct u re wa s
i nt rod u ce d in Ca st -De s ig ne r fo r
MCAD:

Project level
Notebook Computer Casing
Design version
De signe r, Audit or and project inf ormation could be
to manage the geometry data of
recorded and tracked in Cast-Designer for MCAD. All data design
were saved in XML file format and it is possible to
generate customized report easily.
Simulation version
to manage the mesh data of
design

Run version
to manage the simulation
condition and parameters.

Data Exchange Capability Platform Advice Auto Part Auto Part

CAD General : O.S. : Windows XP (32bits), Vista,

STEP/IGES/BREP/STL/DXF Windows 7 (both 32 bits & 64 bits)
Processor :
CAD Advance Intel Pentium IV 2.0G or AMD 2.0G
(with additional license) and above
CATIA/UG NX/PRO-E/ Memory : 2GB and more memory can
SOLID-WORKS get a good performance
Display : Support1280*1024 and
CAE Mesh : above resolution and 128MB display
STL/ANSYS/IDEAS/ memory is required.
CAST-ENGINEER/ Mouse : Three-button engineer
NASTRAN/PATRAN mouse is required. Lamp Cover Auto Oilpanel
Harddisk : 100GB or above free hard
CAM System : STL disk space

DVD-ROM with writable capability for

data backup is also an optional.

References
AALLIED DIE CASTING, AISIN, BLUE RIDGE PRESSURE CASTING, BUELL MOTORCYCLE, CAST
PRODUCTS, CAUDLE MANUFACTURING, CHICAGO WHITE METAL CASTING, CITRON, CONTECH, CTIF,
DAEWOO, FORD MOROR, GM, HITACH PLANT TECKNOLOGIIES, HONDA, ISUZU, MERCURY MARINE, Bathroom Products Machinery Gear
MERIDIAN LIGHTWEIGHT TECHNOLOGIES, MERALDYNE, NIPPON LIGHT METAL COMPANY, NISSAN
INDUSTRY, PACE INDUSTRIES, PACIFIC CAST TECHNOLOGIES, RYOBI LTD, SAMKEE MACHINERY,
TOKYO, TWIN CITY DIE CASTINGS, VOLVO

About Us Partnerships
With the combination of software development, advanced analysis, extensive product development
experience and cost effective local human resources, C3P Engineering Software Internationa Co., Limited
provide industry and manufacturing business with comprehensive solutions and engineering services on a
global basis to meet their expectation in high quality, on-schedule delivery within cost target. Our business
scope covers software development, professional engineering service and application software integration.
More info please visit: www.c3p-group.com

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